DE102017109953A1 - module - Google Patents

Abstract

The invention relates, inter alia, to a sheet-like, rigidly formed component (28), comprising a thermoformed plastic film (14), with a paintable outer surface (29), and at least one lightweight foam reinforcement layer (15), the reinforcing inserts (31) Fibers or fabric mats, and which is disposed on the inner surface (30) of the plastic film (14). The peculiarity is, inter alia, that the plastic is provided by a thermoplastic having a softening temperature of at least 140 °.

Description

The invention first relates to a component according to the preamble of claim 1.

Such components have been developed and manufactured by the Applicant for many decades. They are suitable for different applications.

In a prior art document not assignable, a deep-drawn plastic film is reinforced in the lightweight molded reinforcing layer of polyurethane comprising reinforcing fibers. Such a deep-drawn and lined on its flat surface with a reinforcing layer plastic film is extensively used by the applicant, for example, as a trim part for construction vehicles or agricultural vehicles, eg. B. for the covering of tractor hoods used.

Starting from a component of the preamble of claim 1, the invention has the object, the known device further develop such that it is more versatile.

The invention achieves this object with the features of claim 1, in particular with those of the characterizing part, and is accordingly characterized in that the plastic is provided by a thermoplastic having a softening temperature of at least 140 °.

The principle of the invention is essentially to use instead of known, used for the deep drawing of plastic films plastics such as ABS, which generally have lower softening temperatures, another thermoplastic material having a higher softening temperature, namely a softening temperature of at least 140 °. Such thermoplastics are currently not available for thermoformable plastic films. However, thermoplastics are known that are currently used exclusively for plastic injection molding, and are present in granular form. Such plastics are available, for example, under the trade names Noryl, commercially available, for example, from Sabic, located in Riyadh, Saudi Arabia, or under the trade name Luranyl, obtainable from Romira GmbH, having its registered office in 25421 Pinneberg, Germany.

The two aforementioned plastics, as well as other, the Applicant become known high temperature resistant thermoplastics are basically used only for injection molding. It is not known to form such highly durable thermoplastics into a thermoformable sheet, or to deep draw a sheet made of such material.

The device according to the invention is formed areally. This means in the context of the invention that the component has an extension along an X and a Y direction, which is far greater than the extension of the component in the Z direction. The device may be aligned along a plane, or aligned substantially along a plane. It may have any spatial form, and for example also curved sections, as well as steps, indentations, bulges and discontinuities, etc. have. The basic shape of the component, in particular the contour of the outer surface of the plastic film, is predetermined by a tool shape of the deep-drawing tool.

The device is also formed rigid in its finished state beyond. This means that the component allows no or almost no bending or deflection in the Z direction at least when used as intended.

In the event that the inventive sheet-like, rigidly trained component is used as a vehicle roof module, the component is for example about as rigid as a conventional, existing metal roof element, or a conventional, made of plastic using honeycomb structural component.

The component according to the invention comprises a thermoformed plastic film. The thermoforming sheet is present before the manufacture of the device only in the flat state as a stacked product. It is also conceivable that the plastic film is removed from a roll. The plastic film can before deep drawing a wall thickness between 0.5 and 10 millimeters, preferably between about 1 and 4 Millimeters have wall thickness.

The thermoforming process of the plastic film is carried out in a tool, preferably in a tool with a tool upper part and with a tool lower part. The tool may be preheated to an operating temperature. This operating temperature can be designed above the softening temperature.

However, it is not absolutely necessary for the process of deep drawing that the tool is tempered or is tempered to a temperature above the softening temperature.

The deep-drawn plastic film has an outer surface and an inner surface. The Outer surface is that surface which faces the outside, for example when the component is used in outdoor areas. The outside opposite the inner surface is arranged. On the inner surface of the plastic film, a reinforcing layer is arranged.

The reinforcing layer consists of a lightweight foam, which is provided by a curable, initially liquid, potting compound. In the potting compound before curing the potting compound is an amplification unit, for. B. a plurality of short fibers or long fibers, but possibly also a tissue or scrim, in particular tissue mats, has been introduced. The potting compound may be formed for example by a polyurethane foam.

An embodiment of the foam reinforcing layer takes place after deep drawing. The application can be done in the same tool or in a separate tool.

The outer surface of the plastic film is painted paintable.

According to the invention, the plastic is provided by a thermoplastic which has a particularly high softening temperature of at least 140 °.

Advantageously, the plastic has a softening temperature of at least 145 °.

According to an advantageous embodiment of the invention, the component mounting surfaces, via which it can be bonded by means of a bond with another component. The component may be provided, for example, by a vehicle frame structure.

According to a further advantageous embodiment of the invention, the mounting surfaces are each aligned along a plane. The mounting surfaces are so far as a whole flat, or comprise at least along a plane aligned sections. This facilitates the bonding with another component.

The plastic is provided according to a further advantageous embodiment of the invention of an injection-molded thermoplastic. The injection molding thermoplastic is a thermoplastic that is designed for use in a plastic injection molding process according to its specific applications.

According to a further advantageous embodiment of the invention, the softening temperature is measured as the Vicat softening temperature. The Vicat softening temperature is a special, expertly common and common, as well as reproducible definition of a softening temperature. The temperature is also referred to in the English-speaking world as VST (Vicat softening temperature). According to the so-called Vicat method, a penetration depth in a specimen is measured by means of a circular area needle of one square millimeter with a predetermined test force. This penetration depth test is explicitly intended for thermoplastics.

Common thermoforming films use as plastic ABS (acrylonitrile-butadiene-styrene copolymers) or PMMA (polymethyl methacrylate). These plastics have lower softening temperatures of 108 and 124 ° C, the exact softening temperature of course depends on the plastics used and their admixtures.

It should be noted at this point that in the context of the present patent application the term thermoforming is used for plastic films. This is also referred to as a so-called thermoforming process.

The invention relates, according to a further aspect, to a motor vehicle according to claim 6.

A motor vehicle of the prior art comprises a frame structure on which essential parts of the body are set for the production of the vehicle.

The object of the invention is to provide a motor vehicle which can be manufactured in a simple manner.

This object is achieved by the invention with the features of claim 6, in particular with those of the characterizing part.

The principle of the invention is to provide a motor vehicle, on which a roof module is fixed to the frame structure, which comprises a component according to claim 1 or according to one of the claims back to claim 1. As a result, the production of the vehicle over the prior art can be considerably simplified.

Due to the fact that the plastic consists of a high-temperature-resistant thermoplastic which has a softening temperature of more than 140 °, the motor vehicle can be painted with the roof element connected to the frame structure in an in-line process even at high temperatures. In the in-line process both metallic and plastic components of the vehicle are painted on the body in one go.

If it should be necessary to carry out such a coating under exposure of the component to a high temperature of up to 140 °, the use of a component according to the invention as a roof module in any case prevents softening of the plastic from occurring and, for example, reinforcing structures, such as fibers, or Reinforcing mats, such as deposits, etc., on the outside of the roof module.

The invention relates, according to a further aspect, to a method according to claim 7.

Claim 7 relates to a method for manufacturing a motor vehicle in a plurality of steps. The object of the invention is to provide a method by which motor vehicles can be manufactured in the simplest possible way.

The invention solves this problem with the features of claim 7.

1. a) Bereitstellen einer tiefziehbaren Folie (10) aus einem Kunststoff, der eine Erweichungstemperatur von wenigstens 140° aufweist,
2. b) Tiefziehen der Folie,
3. c) Verstärken der tiefgezogenen Folie (14) durch wenigstens eine Verstärkungsschicht (15) aus einem aufschäumbaren Material,
4. d) Aushärtenlassen des aufschäumbaren Materials,
5. e) Bereitstellen einer Rahmenstruktur (18) eines Kfz,
6. f) Verkleben der Rahmenstruktur (18) mit einem Dachmodul (17), das ein aus der tiefgezogenen Folie (14) und der ausgehärteten Verstärkung gebildetes Bauelement (28) umfasst,
7. g) Lackieren der Karosserie (32) des Kfz zusammen mit dem Dachmodul (17) im In-Line-Verfahren.

The method comprises the following steps:

1. a) providing a thermoformable film (10) made of a plastic which has a softening temperature of at least 140 °,
2. b) thermoforming the film,
3. c) reinforcing the deep-drawn film (14) by at least one reinforcing layer (15) of a foamable material,
4. d) allowing the foamable material to cure,
5. e) providing a frame structure (18) of a motor vehicle,
6. f) adhering the frame structure (18) to a roof module (17) comprising a component (28) formed from the deep-drawn film (14) and the hardened reinforcement,
7. g) painting the body (32) of the vehicle together with the roof module (17) in the in-line process.

To avoid repetition, reference is made to the above statements in an analogous manner with respect to the description of the advantages of the method as an extension of the existing principle, and to explain the features.

• 1 eine tiefziehbare Folie in einer schematischen Querschnittsdarstellung aus einem Thermoplast mit einer hohen Erweichungstemperatur von über 140°,
• 2 in einer Darstellung gemäß 1 eine schematische Schnittdarstellung durch das teilweise geöffnete Werkzeug mit Oberwerkzeug und Unterwerkzeug und der tiefgezogenen Folie der 1,
• 3 in einer teilgeschnittenen schematischen Ansicht die tiefgezogene, auf ihrer Innenseite mit einer Verstärkungsschicht versehene Folie,
• 4 in einer Darstellung gemäß 3, dem gegenüber weiter schematisiert, die tiefgezogene, auf ihrer Innenseite verstärkte Folie während des Trennens von überflüssigen Randbereichen mithilfe eines Trennwerkzeugs,
• 5 in einer schematischen perspektiven Ansicht eine Rahmenstruktur des Kraftfahrzeuges,
• 6 die Rahmenstruktur der 5 mit darauf festgelegtem Dachmodul gemäß 4, und
• 7 in einer teilgeschnittenen schematischen Ansicht ein Kraftfahrzeug zur Verbindung einer Rahmenstruktur mit daran befestigtem Dachmodul gemäß 6 und zusätzlich festgelegten Karosserieteilen während eines In-Line-Lackierverfahrens.

Further advantages of the invention will become apparent from the non-cited subclaims, as well as the following description of the embodiments illustrated in the figures. In the drawings show:

• 1 a deep-drawable film in a schematic cross-sectional view of a thermoplastic with a high softening temperature of over 140 °,
• 2 in a representation according to 1 a schematic sectional view through the partially opened tool with upper tool and lower tool and the thermoformed film of 1 .
• 3 in a partially sectioned schematic view of the deep-drawn, provided on its inside with a reinforcing layer film,
• 4 in a representation according to 3 further schematized on the opposite, the deep-drawn, reinforced on its inside film during the separation of redundant edge areas using a cutting tool,
• 5 in a schematic perspective view of a frame structure of the motor vehicle,
• 6 the frame structure of 5 with roof module fixed thereon according to 4 , and
• 7 in a partially sectioned schematic view of a motor vehicle for connecting a frame structure with it attached roof module according to 6 and additionally fixed body parts during an in-line painting process.

Embodiments of the invention are described by way of example in the following description of the figures, also with reference to the drawings. For reasons of clarity, identical or comparable parts or elements or regions with the same reference numerals, sometimes with the addition of small letters, are also referred to - even if different embodiments are involved.

Features which are described only in relation to an embodiment can be provided in the context of the invention in any other embodiment of the invention. Such modified embodiments are - even if they are not shown in the drawings - covered by the invention.

All disclosed features are essential to the invention. In the disclosure of the application, the disclosure content of the associated priority documents (copy of the prior application) and the cited references and the described devices of the prior art are hereby incorporated in full, also for the purpose of one or more features of these documents in one or more Claims of the present application to include.

A thermoformable thermoforming sheet is indicated in the figures in their entirety by 10, and in 1 shown. The film 10 according to 1 is shown in a schematic side view. In fact, the film preferably has a substantially rectangular flat blank. The film consists of an aforementioned thermoplastic material with a high softening temperature of above 140 °.

2 shows a tool 11 , which can also be called a thermoforming tool. The tool includes an upper tool and a lower tool.

For deep drawing the film 10 this will be in the open tool 11 inserted.

Preferably, the tool 11 heated by an unillustrated in the figures heating to an operating temperature which is above the softening temperature, so z. B. is about a few degrees above the softening temperature.

Further preferably, the tool comprises 11 a blowing device and / or suction device, not shown. For this purpose, it may be provided that the deep-drawn in the tool thermoformable film 10 is attracted by existing in a mold half Luftansaugkanälen. The suction channels are connected to a blower and a pump, which generates a negative pressure, and the film to the contour of the mold 12 attracts.

It is not strictly necessary that the tool, as in 2 shown, mandatory an upper tool 12 and a lower tool 13 must have. The invention also includes manufacturing methods in which the deep-drawing tool 11 only one tool half, z. B. a tool top mold 12 includes, which is contoured formed, and the other tool counterpart is formed flat.

Thus, on the one hand, a deep-drawing process - one also speaks of the thermoforming process - is used for the thermoformable film 10 according to the invention, in which the film in a tool 11 comprising an upper tool and a lower tool, is inserted, and then by a relative movement of the two tool halves 12 . 13 on each other, possibly under additional temperature influence, ie heating the film 10 , a deformation is achieved. Alternatively, a forming process is contemplated in which the thermoformable film 10 without a movement of the tool halves 12 . 13 but is applied exclusively by a blowing or suction after heating to a tool contour, and thereby obtains its final shape.

Once the thermoformable slide 10 to a deep-drawn film 14 deformed, there is the possibility of the thermoformed film 14 on their inside 30 with a reinforcing layer 15 to provide.

The reinforcing layer 15 is a lightweight foam reinforcement layer. This is made of a liquid, curable foam material are placed in the reinforcing fibers as reinforcing elements. The foam composition can be, for example, a conventional polyurethane foam composition, as described in the numerous patent applications of the applicant. For example only, reference is made to the German patent applications for this purpose DE 10 2013 006 300 A1 . DE 10 2013 008 364 A1 . DE 10 2013 008 592 A1 . DE 10 2015 109 897 A1 . DE 10 2016 112 290 A1 ,

The attachment of the reinforcing layer 15 to the thermoformed plastic film 14 can be done in different ways:

According to a first possibility covered by the invention, the deep-drawn film 14 is removed from the mold 11 of the 2 taken and inserted into a second tool, which is not shown in the figures. In this tool, the thermoformed film, for example, with its outside 29 are inserted downwardly, so that an upwardly open cavity is provided. In this interior can now liquid potting compound, together with reinforcing fibers 31 to be introduced. The liquid potting compound can then harden with the tool closed or with the tool open under pressure or without pressure. The component thus formed can then be removed from the mold.

According to a variant of the production instead of reinforcing fibers, for. As glass fibers or carbon fibers, in 3 indicated and by the reference numeral 31 are also scrims, knitted fabrics, braids or the like made of corresponding reinforcing fibers in the foam compound before curing with inserted.

According to a further embodiment of the invention, the reinforcing layer 15 in the same tool with the thermoformed foil 14 connected by the foil 10 to a deep-drawn film 14 has been deep-drawn. For this example, it is conceivable that in the in 2 only indicated interior space between the bottom 30 and the thermoformed film 14 and the tool base 13 a curable foam with reinforcing fibers is introduced. Again, the reinforcing mass with open or closed tool - depending on the application - harden.

The cured reinforcing mass stiffens the component thus formed to a sufficient extent, so that a leichtbauendes, stable, rigid, planar component 28 has been made.

As in the course of thermoforming steps and possibly also in the course of curing of the casting compounds such supernatants on the device 28 arise in 3 With 33a . 33b are designated, can be shown 4 be provided according to the invention, that with the aid of one or more cutting tools 16a . 16b a separation of these supernatant areas 33a . 33b from the device 28 he follows. Only after the separation of the protrusion areas 33a . 33b the finished component is formed. This has an outer surface or outer side 29 on, which consists of a thermoplastic material, with a very high softening temperature of at least 140 °.

The so formed component 28 can now be used as follows:

5 shows - only schematically - a frame structure 18 a motor vehicle to be manufactured 31 , This frame structure comprises a plurality of longitudinal struts extending substantially in the direction of travel (eg. 22a , 22b ), a series of vertical struts not referenced in the figures, and a plurality of horizontal struts (e.g., struts) extending in the vehicle transverse direction 23a . 23b ).

This frame structure forms in finished vehicle 35 according to 7 the passenger compartment 19 Because of the very stiff struts, it protects the occupants from injury in the event of an accident, since they can considerably resist deformation.

The component 28 of the 4 can now be used as a roof module 17 on such a framework structure 18 a car to be manufactured. It shows 6 an embodiment in which the device 28 a roof module 17 in its entirety. Of the invention is also included, if the roof module 28 only a section or part of a roof 34 a car 35 formed.

For attachment of the roof module 17 to the frame structure 18, the frame structure has a plurality of counter-mounting surfaces 21a . 21b . 21c . 21d on. These work with mounting surfaces 20a . 20b on the roof module 17 together.

Of interest is that the mounting surfaces 20a . 20b on the component 28 (see. 4 ) are aligned along a plane. This includes the mounting surfaces 20a . 20b at least the flat portion or partial section include.

The interior mounting surfaces 21a . 21b . 21c . 21d at the frame 18 of the car 35 have a corresponding geometry, so that with the help of a bonding the roof module 17 safe and secure with the frame structure 18 can be connected.

It should be noted that in order to increase the rigidity also further, running in the vehicle transverse direction struts, the 5 are not shown, can be provided.

The roof module married in this way to the frame structure 18 17 forms together with other parts 24a . 24b . 24c after completion, the body of the vehicle. For this purpose, fenders or trim parts 24c . 24d or also doors or door trim parts ( 24a . 24b ) belong.

The body may have plastic parts and metal parts after completion of the vehicle. According to current standards, it is desired in the factory of the car manufacturer to carry out a time-saving and inexpensive painting in one go. So the car is painted altogether, so a painting of metal parts and plastic parts takes place simultaneously.

7 shows only schematically a paint or varnish application device 25 which can be moved along the bodywork for the purpose of the order of color. Alternatively, the vehicle will travel along a fixed paint applicator 25 emotional.

After application provides a holding device 27 for the paint applied 26 Cures according to the prescribed technical parameters (time, temperature).

Because the outer surface 29 of the roof module 17 Made of a temperature-resistant plastic, can now high curing temperatures of up to 140 ° - or slightly higher temperatures - for the drying of the paint 26 be used. This will soften the outer surface 29 the roof module safely prevented. On the body 32 In this respect, no reinforcing fibers (eg reinforcing fibers 31) are distinguished.

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• DE 102013006300 A1 [0050]
• DE 102013008364 A1 [0050]
• DE 102013008592 A1 [0050]
• DE 102015109897 A1 [0050]
• DE 102016112290 A1 [0050]

Claims (7)

A planar flexurally rigid structural member (28) comprising a thermoformed plastic film (14) having a paintable outer surface (29) and at least one lightweight foam backing layer (15) comprising reinforcing liners (31) such as fibers or fabric mats; and disposed on the inner surface (30) of the plastic film (14), characterized in that the plastic is provided by a thermoplastic having a softening temperature of at least 140 °. Component after Claim 1 , characterized in that the component (28) mounting surfaces (20a, 20b), via which it can be bonded by means of a bond with another component (18). Component after Claim 2 , characterized in that the mounting surfaces (20a, 20b) are aligned along a plane. Component according to one of the preceding claims, characterized in that the plastic is provided by an injection-molded thermoplastic. Component according to one of the preceding claims, characterized in that the softening temperature as Vicat softening temperature, in particular according to DIN EN ISO 306, is measured. Vehicle, in particular motor vehicle (31), comprising a frame structure (18) and a roof module (17) fixed thereto, wherein the roof module is a component according to one of Claims 1 to 5 includes. A method of manufacturing a vehicle (31), comprising the following steps: a) providing a thermoformable film (10) made of a plastic which has a softening temperature of at least 140 °, b) thermoforming the film, c) reinforcing the deep-drawn film (14) by at least one reinforcing layer (15) of a foamable material, d) allowing the foamable material to cure, e) providing a frame structure (18) of a motor vehicle, f) adhering the frame structure (18) to a roof module (17) comprising a component (28) formed from the deep-drawn film (14) and the hardened reinforcement, g) painting the body (32) of the vehicle together with the roof module (17) in the in-line process.

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